Carton



Nov. 7, 1950 J. w. cox

CARTON 2 Sheets-Sheet 1 Filed NOV. 22, 1947 INVENTOR. Lfokm W Cox,

J. W. COX

Nov. 7, 1950 CARTON 2 Sheets-Shee t 2 Filed N 6] WIN] Patented Nov. 7, 1950 UNITED STATES I TENT OFFICE CARTON John W. Cox, Chicago, Ill., assignor to Shellmar Products Corporation, Chicago, 111., a, corporation of Delaware 10 Claims.

This invention relates to improvements in molded pulp cartons, particularly cartons for use in packaging eggs.

In the packaging of eggs two types of cellular cartons have been in general commercial use. One type which provides three rows of four cells for receiving a dozen eggs has been successively molded from a watery slurry of paper pulp fibers. The other type which-provides two rows of six cells for the eggs and which is more desirable because it may b conveniently packed, when filled, in the standard 30-dozen capacity egg case or crate, in which eggs are handled and shipped in bulk lots, has been manufactured heretofore from the more expensive paperboard materials which can be cut, creased and foldedto provide the desired cellular structure. A commercially successful molded pulp carton of the 2 x 6 type has not heretofore been produced.

In order to be acceptable commercially the 2 x 6 carton must be made the proper size to fit in the standard-egg case after removal of the fillers and flats from the case, without any reduction in the total number of eggs per case. In

order to provide a molded carton adapted for this type of case packing which will have adequate cell capacit to receive a dozen eggs in properly spaced relation, the carton must be molded without any appreciable laterally extending marginal portions, such as the marginal flange at the meeting line ofthe cover and bottom sections which characterizes the conventional 3 x 4 molded pulp egg carton. Without having the marginal flange to rely upon to'prevent telescopingoi the top and bottom sections, 2 x' 6 carton constructions which have heretofore been proposed have lacked sufiZ- cient' strength and rigidity to withstand vertical stresses and prevent crushing of the eggs when the cartons are placed in superimposed tiers in a case and subjected to the usual handling encountered in shipment. Failure of the previously developed cartons has been due to the fact that relative movement between the topand bottom sections has not been prevented in such cartons and adequate bracing of'the top cover section to prevent its collapse under vertical stresses has not been provided for.

It is a general object of the invention to provide a cellular molded pulp egg carton which overcomes the deficiencies inherent in the 2 X 6 molded pulp egg cartons previously developed, which meets all the requirements or" a strong, compact rigid container of the proper size to fit in the standard case, which houses the eggs in such a manner that the percentage oiegg breakage in shipment is" materially reduced and which may be more economically produced than the conventional paperboard egg carton.

It is a specific object of the invention to provide a cellular molded pulp egg carton of the proper size to fit within a standard egg case and having an adequat topbracing structure combined with a locking means which cooperates with the bracing structure to prevent any appreciable relative movement between the top and bottom sections of the carton.

It is a further object of the invention to provide a cellular molded pulp egg carton of the type described having a flap formed integral with the marginal edg of the bottomsection which flap extends substantially the length of the top section when the carton is in closed condition and lies adjacent the inner front wall ofthe top section with its edge in substantially abutting relation with the top wall of the top section to reinforce and rigidify the carton and effectively prevent the failure of the carton when subjected to the vertical stresses encountered in the customary shipment and handling 0f.a plurality of such cartons arranged in superimposed tiers in standard egg cases.

It is a still further object of the invention to provide a molded pulp egg carton of the type described wherein the bottom section of the carton is provided with an integrally molded panel along a marginal edge which is adapted to be inserted in the top or cover section in juxtaposed relation with a generally vertical wall of the section and with its edge in substantial abutting relation with the planar top wall of the cove section and wherein integral locking elements are provided on the marginal edge of a wall of the cover section which are adapted to interlockingly engage, from the outside of the carton, in apertures provided in the adjacent wall of the bottom section to rigidly brace and lock the cover section to the bottom section of the carton and prevent any appreciable relative movement between the sections. 1

It is another object of the invention to provide a molded pulp carton of the type described which embodies the improved cover bracing flap and cooperating locking means and which is also divisible transversel of the carton to provide cellular carton sections having less than a dozen e s therein.

These and other objects of the invention will be apparent to those skilled in this art from a consideration of the preferred form of the inin the accompanying drawing, wherein:

Fig. 1 is a plan view of a 2 x 6 carton which embodies the principles of the invention;

Fig. 2 is an end elevation with the cover section hinged to an upright position and with the bracing panel bent to position for insertion in the cover section;

Fig. 3 is a transverse section taken on the line 33 of Fig. 1;

Fig. 4 is a front elevation of a divisible form of 2 X 6 carton having incorporated therein the bracing and locking feature of the invention;

Fig. 5 is a plan view of the divisible carton shown in Fig. 4;

Fig. 6 is a perspective view of the divisible carton with the cover in partially closed condition; and

Fig. 7 is a transverse section taken on the line 1-! of Fig. 5.

Referring to Figs. 1 to 3 of the drawings, there is illustrated a 2 X 6 carton which embodies the principles of the invention and which is capable of being readily molded from a watery slurry of paper pulp fibers.

The illustrated carton comprises a cellular bottom section I and a top or cover section I I'. The carton bottom section I0 is formed to provide two longitudinal rows of six cells each for accommodating a dozen eggs therein. Each egg-receiving cell is generally octagonal in shape and is defined by a bottom and upwardly sloping integral wall forming panel members, with adjacent panel members merging or connected at their upper ends by web portions which define partitioning formations extending longitudinally and transversely between the cells, in the manner described herewith.

The cellular bottom section II] comprises front and rear, end, or corner, cells I2 and I3 which are disposed in transverse alignment to form a pair of cells at each end of the section and intermediate, front and rear cells I4 and I which are also disposed in transverse alignment to form four intermediate pairs of cells between the end pairs. The carton is symmetrical about a transverse center line and the four rear intermediate cells I5 are identical while the four front intermediate cells I4 are also identical except for certain adjoining wall structure which will be described.

The structure of each of the end cells I2 and I3 is the same. These cells differ only in their position relative to the adjoining cells. Outer panels I5, I5, I8 of the front end cell I2 and corresponding outer panels I9, 20, 2| of the rear end cell I3 extend upwardly to the substantially marginless upper edge of the bottom section Ill and define front and rear corner and end side wall forming portions for the section I 0. Panels 22 and 23 which adjoin panels I8 and 2I, respectively, extend upwardly and are integrally joined at their upper edges with a triangular web section 24 which extends inwardly from the top of the end edge of the section I U to define the end portion of the longitudinal partition formation. Panels 25 and 26 of cells I2 and I3 extend upwardly and merge below the plane of the top edge of the section Ill to define an upstanding ridge-like portion of the longitudinal partition formation which adjoins the end portion thereof. A like partition formation is provided by the corresponding upwardly merging wall panels of each pair of transversely aligned cells. Panels 2! and 28 of cells I2 and I3 and the ad.-

jacent panels 29 and 30 of the adjoining intermediate cells I4 and I5, respectively, extend upwardly and are integrally joined at their upper edges by a rectangular horizontal web portion 3| to define a truncated intermediate partition formation. A like partition formation is defined by the corresponding adjacent wall panels of each set of four adjoining cells. These truncated formations combined with the triangle end partition formations and the intermediate ridge-like partition formations provide the longitudinal or medial partition which divides the cells into two longitudinal rows.

The wall forming panels 32 and 33 of the cells I2 and I3 extend upwardly and merge with the adjacent wall forming panels 34 and 35 of the adjoining intermediate cells I4 and IE to form ridge-like partition portions extending transversely between the end pair of cells I2 and I 3 and the adjacent intermediate pair of cells I4 and I5. The wall forming panels 36 and 31 of the cells I2 and I3 extend upwardly in merging relation with the adjacent wall forming panels 38 and 39 of the adjoining intermediate cells I4 and I5 and are integrally joined with triangular webs 40 and 4|, respectively, which extend inwardly from the front and rear top edges of section ID, to form triangular transverse end partition formations. These formations combined with the central truncated partition formation and the connecting transverse ridgee 1ike partition formations define the transverse partition between the pairs of cells. Each pair of cells is separated from the adjoining pair of cells by a like transverse partition. All the cells are provided with bottom members which integrally join the bottom edges of the wall forming panels and which constitute the bottom or supporting face of the carton.

The end wall forming panels I8 and 2| of the end cells I2 and I3 constitute the upwardly and outwardly sloping outer end wall faces or surfaces of the section I0 while the front and rear wall forming panels I6 and I9 thereof combined with the corresponding wall forming panels of the intermediate cells I4 and I5 constitute the outer side wall faces or surfaces of the section II].

The carton cover section II is formed by integrally connected planar top wall 42, front and back side walls 43, 44 and end wall 45, 46. The front, side and end walls 43, Hand 46 extend outwardly in angular relation to the top wall 42 and terminate in a substantially fiangeless lower edge while the rear wall 44 extends in the same angular relation and is integrally connected by a hinge joint 41 with the upper edge of the rear wall formation of the bottom section ID. The end corners are formed to correspond with the end corners of the bottom section III.

A cover bracing and reinforcing panel or flap member 48 is provided along the top edge of the front wall of the carton section Ill. The panel 48 which is preferably molded substantially in the plane of the top edge of the section extends substantially the full length of the carton front wall and is adapted to be hinged to an upwardly extending position (Fig. 2) for insertion in the carton cover section II where it is received in juxtaposed relation to the front wall 43 of the latter with its free edge 49 in substantially abutting relation with the inner surface of the top wall 42 of the cover section when the cover section is in fully closed position.

The front wall 43 of the cover section II is provided with a pair of longitudinally spacedintegrally molded locking tabs or tongue formations 50 each comprisinga body portion 5|, a reduced neck portion 52 and a wedge shaped head 53'which are molded in outstanding relation but whichare adapted to be folded downwardly about the meeting edges of the bottom and cover sections of the carton when the cover section is in closed position.

The front wall of the bottom section Ill i provided with a pair of locking apertures 54 for cooperation with the locking tabs 50. The apertures 54 are located in triangular partition formations between adjacent intermediate front cells I4. A generally horizontal ledge 55 is formed intermediate the bottom of the section l and the top edge thereof which extends inwardly from a generally vertical wall section 56. The wall section 56 extends downwardly between the upper portions of the outer wall forming panels of the adjacent cells l4 and substantially in the same plane a the panels. The bottom portion of the aperture 54, which is in the horizontal ledge 55, is triangular while the upper portion of the aperture 54, which is in the wall section 56, is generally rectangular and somewhat narrower at the upper end thereof.

When the cover section II is hinged to the closed position with the bracing flap 48 in proper position within the cover section, the locking tabs 50 are bent downwardly around or over the meeting edge of the front wall portions of the bottom and cover sections and the heads 53 thereof are inserted in the apertures 54 in interlocking relation therewith. The bracing flap 48 is positioned between the top portions of the eggs positioned in the front cells l2, l4 and the cover front wall 43 and is retained in bracing relation with the cover section by the eggs. The bottom edges of the cover end walls 45 and 46 are supported on the inwardly extending abutment forming webs 24. The carton sections are held in closed relation by means of the locking tab 55 which are securely fastened with their heads 53 in interlocking engagement in the apertures 54. The locking tab heads 53 are engaged in the apertures 54 by a downward and inward movement which positions the heads 53 in the space between adjacent eggs in the carton without danger of breaking the eggs. The arrangement provides a strong, rigid carton which can be successfully molded, which can be packed in the standard egg case as desired and which resists collapse and telescoping of the carton sections in a highly satisfactory manner.

The carton which is shown in Figs. 4 to 6 illustrates the invention embodied in a divisible carton. It comprises a cellular bottom section 60 and a cover section which is hingedly connected thereto along the top edge of the rear wall thereof.

The bottom section 55 is molded to provide two longitudinal parallel rows of egg receiving cells 62 which are transversely aligned in pairs and separated by partition formations defined by merging wall forming panels, in the same manner as in the carton structure shown in Figs. 1 to 3, except for the ridge-like portions of the partition formation between the respective cells, which are flattened along the top edges of the merging wall forming panels constituting the same. The central transverse partition formation is provided with a perforated or weakened twoportions of six cells each.

The carton cover section 6| isthe. same asin the non-divisible carton of Figs. 1 to 3 except for an inwardly extending dividin groove or valley 53 which extends transversely of the top and sidewalls thereof on the transverse center line and'isprovided with a perforated or weakened line 54 to facilitate separation of the carton into the two portions.

The carton bottom section 60 is provided along the upper edge of the front wall thereof with bracing panel members 64, which correspond to the bracing panel member 41 of the nondivisible carton being separated adjacent the transverse center line by a space 66 sufficient to accommodate the front end 61 of the cover separating groove 53.

Thecover sectionlil is provided with looking tabs 68 which are identical in form with the corresponding tabs 59 in the non-divisible carton. The bottom section 50 is provided with cooperating apertures 69, which are identical with the apertures 54 for receiving in interlocking relation the heads of the'locking tabs 68. The apertures 69- are located between the front cells which are immediately adjacent the transverse dividing line 62 of'the carton so that when the tabs 58 are engaged therein the lock is closely adjacent the inner ends of the'separ-ated portions of the carton after it 'is divided. This construction insures greater rigidity in the separated portions.

The divisible carton is illustrated as separable along a transverse center line but the division may be along any other line or lines to divide the carton into portions of any desired size, the cover bracing flaps and the latching tabs being arrangedas' required by the location of the dividing line orlines to best serve the bracing and locking functions.

While specific details of construction and materials have been referred to in describing the illustrated forms of the invention, it will be understood that other details of construction and other materials maybe resorted to within the spirit of the invention.

I claim:

1. A molded pulp carton, comprising a cellular bottom section having a cover-locking detent butween adjacent cells, a non-cellular, tray-like cover section having top, front, rear and end walls, said cover being hinged to said bottom section along said rear wall, a cover bracing flap hinged to said bottom section and extending upwardly along the inside of the front wall of said cover section into generally upright bracing position with respect thereto when the sections are in closed relation, and a cover locking tab integral with the front wall of said cover, said tab being positioned in interlocking engagement with the detent in said bottom section from the outside of said carton.

'2. A molded pulp carton, comprising a cellular bottom section, a non-cellular, tray-like cover section having a planar top and outwardly and downwardly extending planar front, rear and end walls, said cover section being hinged to said bottom section along said rear wall, a cover bracing flap hinged to the front wall of said bottom section and extending upwardly and inwardly along the inside of the front wall of said cover section to a position abutting the under side of said planar top when said sections are in closed relation, and a cover-locking tab integrally hinged to the front wall of said cover section to position the same between adjacent cells in said bottom section, said bottom section having a detent for interlocking engagement with said tab, and said tab being engaged with said detent from the outside of said carton.

3. A molded pulp carton, comprising a bottom section having a row of downwardly extending cells spaced apart at their lower portion, said bottom section having a tab-receiving opening between adjacent cells, a non-cellular, tray-like cover section having top, front, rear and end walls, said cover section being hinged to said bottom section along said rear wall, an integrally formed extension on said bottom section form ing a cover bracing panel adjacent the front wall of said cover, said panel being upwardly folded along the inside of said front wall into upright bracing position with respect to said cover when said'sections are in closed relation, and an integral extension of said front wall forming a locking tab, said tab being interlocked with the opening in said bottom section from the outside of said carton.

4. A molded pulp carton, comprising a bottom sectio divided into cells, a non-cellular, traylike cover section havin a top and outwardly and downwardly extending front, rear and end walls, an integral cover bracing flange on one side of said bottom section and of substantially the same 7 height as the height of the front wall of said cover section, said flange extending upwardly along the inside of said front wall into bracing relation with respect to said cover section, and means exteriorly movable when the carton sections are in closed relation for securing said bottom and cover sections in closed position.

5. A divisible molded pulp carton, comprising a bottom section having two rows of separated cells, two cover bracing flange sections integrally hinged along the front side of said bottom section, a non-cellular, tray-like cover section having a top and downwardly extending front, rear and end walls and having a transverse depression between the ends thereof, said flange sections having a space therebetween in alignment with the transverse depression in the cover section when the carton sections are in closed relation, said flange sections extending upwardly on the inside of the front wall of said cover section into bracing relation therewith, and means integral with said cover section and exteriorly movable into locking relation to said bottom section when the carton sections are in closed relation for securing said cover and bottom sections in closed relation, said securing means being arranged on opposite sides of the space between said flange sections whereby upon division of the carton the bottom and cover sections of the separated portions will be maintained in closed relation,

6. A molded pulp carton, comprising a bottom section having parallel rows of downwardly extending cells, adjacent cells in each row merging at their upper portions and being separated at their lower portions, horizontal cover bracing flange means integrally connected to the front side of said bottom section and composed of adjacent parts extending outwardly from a central portion of the carton between adjacent cells, said bottom section having hook-receiving openings between the cells next adjacent the inner portion of each of said parts, a non-cellular, tray-like cover section hinged to the rear side of said bot-v tom and having a transverse depression adjacent the inner portions of said flange parts between said openings, and inte ral hooks on said cover for engagement with the openings in said bottom section from the outside thereof, said flange parts extending upwardly along the inner side of said cover into bracing relation with the upper portion thereof.

7. A molded pulp carton comprising a bottom section having side and end walls and means subdividing the space within said walls into cells, said means including transverse partition elements extending between and connected to said side walls, said bottom section being provided with a locking aperture in one of the side walls thereof between adjacent cells, a bracing flange hinged to said one wall above said aperture, a non-cellular, tray-like cover section having a top and side and end walls, one of said cover walls being hinged to'the bottom section, said cover section being positionable with another wall thereof encompassing said flange in side-byside relation in the closed position of said sections, said flange being of sufficient height to marginally engage and brace said cover section top in said closed position, and a locking element integrally projecting from said cover as a marginal extension thereof in alignment with said aperture and engaging the same to secure said cover and bottom sections in said closed position.

8. A molded pulp carton comprising a bottom section having side and end walls and means subdividing the space within said walls into cells, said means including transverse partition elements extending between and connected to said side walls, said bottom section being provided with a locking formation in one of the side walls thereof between adjacent cells, a bracing flange hinged to said one wall above said formation, a non-cellular, tray-like cover section having a top and side and end walls, one of said cover section walls being hinged to the bottom section, said cover section being positionable with another wall thereof encompassing said flange in side-byside relation in the closed position of said sections, said flange being disposed at an angle to its associated wall in said closed position and being of suflicient height to marginally engage and brace said cover section top in said closed position, and a locking element projecting from said cover as a marginal extension thereof in alignment with said formation and engaging the same to secure said cover and bottom sections in said closed position.

9. A molded pulp carton comprising a cellular bottom section, a non-cellular, tray-like cover section provided with a planar top, said sections each being provided with integrally connected front, rear and end walls, the rear wall of said cover section being integrally hinged to the rear wall of said bottom section, a cover bracing flange integrally hinged along the front wall of said bottom section, and positionable within the front wall of said cover section and in side-by-side contact therewith throughout the entire inside height of said cover section front Wall, said flange being of suflicient height to engage and brace the top of said cover section when said sections are in closed locked relation, and means to lock said sections in said relation.

10. A molded pulp carton comprising a cellular bottom section, a non-cellular tray-like cover section, said sections each including integrally connected front, rear and end walls and the cover section having a top panel extending between and integral with the walls thereof, the rear wall of said cover section being hinged to the rear wall integrally hinged along the front wall ofsaid 9 cellular bottom section, said flange being positionable within the front wall of said non-cellular cover section in side-by-side contact with said front wall in the closed relation of the sections and being of sufiicient height to engage and brace the top panel of said. tray-like cover section in said closed relation.

JOHN W. COX.

REFERENCES CITED Number 10 UNITED STATES PATENTS Name 1 Date Hartley et al "Apr. 24, 1917 Koppelman Feb. 23, 1932 De Reamer Nov. 17, 1936 Farnham Apr. 27, 1937 Koppelman Sept. 14, 1937 Read Nov, 30, 1937 Schwartzberg June 2, 1942 

